Module maintenance system

ABSTRACT

A module maintenance system includes a battery module comprising at least a first battery cell and a second battery cell, and a charging device comprising a bulk output and an equalization output. The battery module has a series configuration and a parallel configuration. In the parallel configuration, the charging device outputs a first voltage to the equalization output to equalize charge levels of the first and second battery cells. In the series configuration, the charging device outputs a second voltage to the bulk output to modify charge levels of the first and second battery cells, wherein the second voltage is greater than the first voltage.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of U.S. Pat. No. 10,431,993, issuedOct. 1, 2019, and titled “Module Maintenance System,” which is adivisional of U.S. Pat. No. 10,063,069, issued Aug. 28, 2018, and titled“Module Maintenance System,” which is a continuation-in-part of U.S.Patent Application Publication No. 2015/0086825, published on Mar. 26,2015, and titled “Module Backbone System,” which claims priority to U.S.Provisional Patent Application No. 61/960,715, filed Sep. 24, 2013, andtitled “Module Backbone System.” Additionally, U.S. Pat. No. 10,063,069claims priority to U.S. Provisional Application No. 61/997,186, filed onMay 23, 2014, and titled “Module Maintenance System.” Each patent andapplication listed above is incorporated herein by reference in itsentirety.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to a battery system (e.g., battery pack),particularly a battery system for high voltage applications (e.g., 480volts).

2. Description of Related Art

Some battery systems may use multiple battery cells. In such systems,battery cells may have different electrical characteristics that mayimpact a performance of the battery system.

Therefore, there is a need in the art for a battery system that mayaccount for electrical characteristics of a battery cell.

SUMMARY OF THE INVENTION

The proposed invention is directed to a battery system. In someembodiments, the battery system may include a battery module formed oftwelve cells, but this technology can use a battery module having anynumber of battery cells. In one example, a battery module has a nominalvoltage of 40 volts (V), 260 ampere-hour (Ah), and 10 kilowatt hour(kWh). In the example, a battery cell of the battery module may have anominal voltage of 3.33 volts (V). It should be understood thatembodiments may use any suitable battery cell types, manufacturers,technologies, and the like.

Embodiments include a battery module, a rig, and a charging device. Thebattery module includes an enclosure and at least a first battery celland a second battery cell. The first and second battery cells aredisposed in a cavity of the enclosure. The rig includes a lid and a setof buses. The set of buses are attached to the lid. The charging deviceis for charging the first and second battery cells. The battery modulehas a series configuration and a parallel configuration. In the seriesconfiguration, the lid of the rig is spaced apart from the enclosure andthe set of buses of the rig are spaced apart from the first and secondbattery cells. In the series configuration, one or more bus bars couplethe first and second battery cells in series and the charging devicemodifies charge levels of the first and second battery cells using theone or more bus bars. In the parallel configuration, the lid of the rigattaches to the enclosure of the battery module such that the set ofbuses of the rig couple to the first and second battery cells and thecharging device modifies charge levels of the first and second batterycells using the set of buses.

In one aspect, an apparatus includes a battery module, a rig, and acharging device. The battery module includes at least a first batterycell and a second battery cell. The rig includes a set of buses forconnecting with the first and second battery cells. The charging deviceincludes a bulk output and an equalization output. The battery modulehas a series configuration and a parallel configuration. In the parallelconfiguration, the rig is disposed onto the battery module such that theset of buses couple the first and second battery cells in parallel. Inthe parallel configuration, the equalization output is coupled to theset of buses and the charging device outputs a first voltage to theequalization output to equalize charge levels of the first and secondbattery cells. In the series configuration, one or more bus bars couplethe first and second battery cells in series with the bulk output andthe charging device outputs a second voltage to the bulk output tomodify charge levels of the first and second battery cells. The secondvoltage is greater than the first voltage.

In another aspect, an apparatus includes a battery module and a rig. Thebattery module including an enclosure and at least a first battery celland a second battery cell. The first and second battery cells aredisposed in a cavity of the enclosure. The first battery cell includes afirst anode and a first cathode and the second battery cell includes asecond anode and a second cathode. The rig includes a lid, a first bushaving a first set of contact elements, and a second bus having a secondset of contact elements. The lid is secured onto the cavity such thatthe first set of contact elements are coupled to the first anode and thesecond anode. The lid is secured onto the cavity such that the secondset of contact elements are coupled to the first cathode and the secondcathode.

Other systems, methods, features and advantages of the invention willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description and this summary, bewithin the scope of the invention, and be protected by the followingclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is a schematic view of a module maintenance system, in accordancewith an exemplary embodiment;

FIG. 2 is a schematic view of a charging device, in accordance with anexemplary embodiment;

FIG. 3 is a schematic view of a module maintenance system in a firstarrangement, in accordance with an exemplary embodiment;

FIG. 4 is a schematic view of a module maintenance system in a secondarrangement, in accordance with an exemplary embodiment;

FIG. 5 is a schematic view of a module maintenance system in a thirdarrangement, in accordance with an exemplary embodiment;

FIG. 6 is a schematic view of a module maintenance system in a fourtharrangement, in accordance with an exemplary embodiment;

FIG. 7 is a schematic view of a module maintenance system in a fiftharrangement, in accordance with an exemplary embodiment;

FIG. 8 is a schematic view of a battery module, in accordance with anexemplary embodiment;

FIG. 9 is a schematic view of bus bars connecting battery cells of thebattery module of FIG. 8, in accordance with an exemplary embodiment;

FIG. 10 is a schematic view of a rig for connecting battery cells of thebattery module of FIG. 8, in accordance with an exemplary embodiment;

FIG. 11 is an exploded view of the rig of FIG. 10, in accordance with anexemplary embodiment;

FIG. 12 is a schematic view of contact elements of the rig of FIG. 10,in accordance with an exemplary embodiment;

FIG. 13 is a schematic view of positioning the rig of FIG. 10 on anenclosure of the battery module of FIG. 8, in accordance with anexemplary embodiment;

FIG. 14 is a schematic view of coupling contact elements of the rig ofFIG. 10 to bus bars of the battery module of FIG. 8, in accordance withan exemplary embodiment;

FIG. 15 is a schematic view of contact elements of the rig of FIG. 10being held in direct contact with bus bars of the battery module of FIG.8, in accordance with an exemplary embodiment;

FIG. 16 is a schematic view of the rig of FIG. 10 being disposed onto anenclosure of the battery module of FIG. 8, in accordance with anexemplary embodiment;

FIG. 17 is a schematic view of a module maintenance system having thebattery module in a series configuration, in which a charging device isin a discharging state to discharge the battery module of FIG. 8, inaccordance with an exemplary embodiment;

FIG. 18 is a schematic view of a module maintenance system afterdischarging the battery module of FIG. 8, in accordance with anexemplary embodiment;

FIG. 19 is a schematic view of a module maintenance system having thebattery module in a series configuration, in which a charging device isin a charging state to bulk charge a series string of battery cells ofthe battery module of FIG. 8, in accordance with an exemplaryembodiment;

FIG. 20 is a schematic view of a module maintenance system after bulkcharging a series string of battery cells of the battery module of FIG.8, in accordance with an exemplary embodiment;

FIG. 21 is a schematic view of a module maintenance system having thebattery module in a parallel configuration, in which a charging deviceuses a rig to charge each battery cell of the battery module of FIG. 8,in accordance with an exemplary embodiment; and

FIG. 22 is a schematic view of a module maintenance system aftercharging each battery cell of the battery module of FIG. 8, inaccordance with an exemplary embodiment.

DETAILED DESCRIPTION

Embodiments may simplify maintenance (e.g., charge, discharge, batterycell balancing, etc.) of a battery module containing a set of batterycells (e.g., 12 battery cells). For example, a module maintenance systemmay permit bulk charging (e.g., charging the battery cells in series) byconnecting a bulk output of a charging device to terminals of a batterymodule. In the example, a module maintenance system may also permit anequalization of voltages of the battery cells of the battery module bysecuring a rig onto the battery module and connecting an equalizationoutput of the charging device to the rig.

A module maintenance system may include any suitable components tofacilitate maintenance of battery modules. Referring to FIG. 1, modulemaintenance system 100 includes charging device 102, battery module 104,battery module 106, and alternating current (AC) supply (e.g., electricgrid connection) 110. In other embodiments, a module maintenance systemmay include different components. For example, in some embodiments,charging device 102 of module maintenance system 100 charges a singlebattery module (e.g., 104 or 106). In another example, as shown in FIG.1, module maintenance system 100 may include data port 134 to permitaccess to one or more networks 144 (e.g., internet), remote terminal142, and remote data store 140, as described further below.

The AC supply 110 may be any voltage level or current capacity. Forexample, the AC supply 110 may be a 480/600 volt AC voltage. In anotherexample, the AC supply 110 may be a 277/480 volt AC voltage. In someexamples, the AC supply 110 may be a 347/600 volt AC voltage. The ACsupply 110 may be part of a commercial grid. For example, the AC supply110 may include a regional transmission network and be operated at aparticular frequency (e.g., 50 Hz, 60 Hz, etc.) The AC supply 110 mayuse various numbers of phases (e.g., single phase, three phase, etc.).

The battery module may be configured to use any suitable number ofbattery cells. In some embodiments, a battery module (e.g., 104, 106),etc.) may include two or more battery cells. For example, battery module104 may include sixteen battery cells, twelve battery cells, eightbattery cells, and the like. As used herein, a battery cell may use anysuitable battery technology. Examples of a battery cell includecapacitors, ultra-capacitors, and electrochemical cells. Examples ofelectrochemical cells include primary (e.g., single use) and secondary(e.g., rechargeable). Examples of secondary electrochemical cellsinclude lead-acid, valve regulated lead-acid (VRLA), gel, absorbed glassmat (AGM), nickel-cadmium (NiCd), nickel-zinc (NiZn), nickel metalhydride (NiMH), lithium-ion (Li-ion), and the like. A battery cell mayhave various voltage levels. For example, a battery cell of batterymodule 104 may have a voltage of less than 40 volts, less than 20 volts,less than 10 volts, less than 5 volts, 3.3 volts, less than 3.3 volts,and the like. Similarly, the battery cell may have various energycapacity levels. For example, a battery cell of battery module 104 mayhave a capacity of more than 13 ampere-hour, more than 10 ampere-hour,more than 20 ampere-hour, more than 25 ampere-hour, and the like.

The charging device 102 may include any suitable components tofacilitate a maintenance of a battery module (e.g., 104, 106, etc.).Referring to FIG. 1, charging device 102 may include battery maintenancesystem (BMS) controller 120, parallel section 122, series section 124,and local terminal 126 (e.g., computing device). In other embodiments,charging device 102 may be different. For example, local terminal 126may be omitted.

In those instances where a local terminal is included, any suitabletechnology may be used. As used herein, a terminal may include tocomputing resources of a single computer, a portion of the computingresources of a single computer, and/or two or more computers incommunication with one another. For example, local terminal 126 may be asingle computer (desktop, laptop, notebook, etc.), server, mobile device(e.g., tablet, smart phone, etc.), and the like. In some embodiments,any of these resources may be operated by one or more human users. Insome embodiments, a terminal may also include one or more storagedevices including, but not limited to, magnetic, optical,magneto-optical, and/or memory, including volatile memory andnon-volatile memory. For example, local terminal 126 may include a solidstate drive and non-volatile memory.

In some embodiments, the local terminal may be configured to determineelectrical characteristics of one or more battery cells of a batterymodule. In some embodiments, the local terminal may measure a chargeand/or discharge rate of battery module. In some embodiments, the localterminal may utilize one or more sensor circuits. An example of a sensorcircuit may include one or more features described in Kasaba et al.,U.S. patent application Ser. No. 14/529,853, filed on Oct. 31, 2014, andtitled “System and Method for Battery Pack Charging and Remote Access,”the entirety of which is incorporated herein by reference. For example,a sensor circuit may include a voltage sensor and/or a current sensor.In the example, local terminal 126 may facilitate measurement andrecording of a discharge rate and/or a charge rate of a battery cell ofbattery module 104 and/or battery module 106 using such a sensorcircuit. Moreover, in the example, local terminal 126 may store datarelated to the measurements and/or rates in data store 150 and/ortransmit the data related to the measurements and/or rates to remotedata store 140 using one or more networks 144. In some embodiments, thecontroller may modify a charging and/or discharging rate of a batterycell of battery module to determine electrical characteristics of thebattery cell. For example, controller 120 may rapidly charge and/ordischarge battery cell 912 to facilitate the testing of electricalcharacteristics of battery cell 912 as well as battery module 800.

The battery maintenance controller 120 may include one or moreprocessors and have access to memory including instructions to operatecharging device 102. For example, controller 120 may be configured tointeract with local terminal 126 to transmit a log of data store 150. Inanother example, controller 120 may be configured to receive controlinstructions and to transmit the control instructions to parallelsection 122 and/or series section 124.

The one or more networks 144 may include any number of devices and mayuse various protocols. In some embodiments, one or more networks 144 mayinclude a connection to an internet service provider and utilize aninternet protocol suite (e.g., TCP/IP). As shown in FIG. 1, chargingdevice 102 may include data port 134 to connect the charging device 102with remote terminal 142 and/or the remote data store 140 using the oneor more networks 144.

In some embodiments, the charging device may charge battery modulesusing electrical power received from an electric grid. Referring to FIG.1, input connection 132 electronically couples charging device 102 to ACsupply 110. As used herein, electronically couple may refer to anyelectronically conductive connection. In the example, charging device102 converts the AC power received from the AC supply 110 to chargebattery module 106 and/or battery module 104. In some embodiments, thecharging device may discharge battery modules onto an electric grid, asdescribed further below. In other embodiments, the charging device maydischarge one or more battery cells of a battery module to charge one ormore other battery cells of the battery module or one or more batterycells of another battery module (not shown).

In some embodiments, the charging device may maintain a charge level(e.g., charge and/or discharge) of a battery module using a bulk output.Referring to FIG. 1, bulk output 130 may electronically couple seriessection 124 of charging device 102 to one or more battery cells ofbattery module 106. In some embodiments, the charging device maymaintain a charge level (e.g., charge and/or discharge) of a batterymodule using an equalization connector. Referring to FIG. 1,equalization output 128 may electronically couple parallel section 122of charging device 102 to one or more battery cells of battery module104.

In some embodiments the parallel section of a charging device mayinclude a first converter for charging battery cells in parallel.Referring to FIG. 2, first converter 222 may receive power from an ACsystem associated with AC supply 110 (see FIG. 1). For example, firstconverter 222 may support various voltages, currents, power levels,frequencies (e.g., 50 Hz, 60 Hz), number of phases, and the like. In theexample, first converter 222 may support a 480/600 volt AC voltage. Insome instances, a transformer (not shown) may be used to adjust an inputvoltage to account for regional differences. For example, a firsttransformer is used for a 480/600 volt AC voltage for input into firstconverter 222 and a second transformer is used for a 347/600 volt ACvoltage for input into first converter 222. As such, first converter 222may support various AC voltages without impacting conversion between theAC and DC systems.

Similarly, the first converter may support various DC systems. Forexample, first converter 222 may support a DC system associated with oneor more battery cells of battery module 104 and/or one or more batterycells of battery module 106. In some embodiments, first converter 222may output a voltage (e.g., operating voltage, nominal voltage, etc.) ofa battery cell. For example, each battery cell of battery module 104 mayhave a nominal voltage of 3.3 volts. In the example, first converter 222may output 3.3 volts at equalization output 128. In other examples,first converter 222 may output other voltages.

The first converter may use various types of converter topologiesincluding, for example, buck, boost, buck-boost, and the like.Similarly, the first converter may use various types of invertertopologies including, for example, a grid-tie inverter system, a squarewave, modified square wave, modified sine wave, pure sine wave, and thelike. The topologies used in the first converter may support abi-directional function. As used herein, a bi-directional DC/ACconverter may include a converter configured to (1) convert from the DCsystem to the AC system and (2) convert from the AC system to the DCsystem. In some embodiments, the first converter may include an AC to DCconverter for converting from the AC system to the DC system and a DC toAC inverter for converting from the DC system to the AC system. In otherembodiments, a single converter is used to convert between the AC andthe DC systems.

In some embodiments the series section of a charging device may includea second converter for charging battery cells in series. Referring toFIG. 2, series section 124 may include second converter 224. In someembodiments, second converter 224 is substantially similar to firstconverter 222 except that the first converter and second converter 224output different voltages. In some embodiments, first converter 222 mayoutput a charge voltage (e.g., operating voltage, nominal voltage, etc.)of a battery cell of a battery module (e.g., 104) and second converter224 may output a charge voltage (e.g., operating voltage, nominalvoltage, etc.) of series string of battery cells of a battery module(e.g., 104). For example, each of the twelve battery cells of batterymodule 104 may be connected in series and each of the twelve batterycells of battery module 104 may have a nominal voltage of 3.3 volts,thereby resulting in battery module 104 having a nominal voltage ofabout 40 volts. In the example, first converter 222 may output 3.3 voltsat equalization output 128 while second converter may output 40 volts atbulk output 130.

In those instances where the first converter and/or the second converterutilize a switching topology, any suitable switching control may be usedto facilitate a selection of voltages output on the bulk output and/orequalization output. In some embodiments, controller 120 may selectivelyswitch the first converter of the parallel section and/or the secondconverter of the series section to suitable voltage levels. For example,controller 120 may be programmed by a human user to switch firstconverter 222 to output a first voltage on equalization output 128 andto switch second converter 224 to output a second voltage on bulk output130. In the example, the first voltage (e.g., 3.3 volts) may be lessthan the second voltage (e.g., 39.6 volts).

In some embodiments, the series section may include a discharge circuit.In some embodiments, the discharge circuit may include a resistiveelement, such as a fixed or variable resistor (e.g., wire wound, gridresistor, etc.), and a switch, such as a transistor(metal-oxide-semiconductor field-effect transistor, bipolar junctiontransistor, insulated-gate bipolar transistor, etc.). Referring to FIG.2, discharge circuit 226 may include resistive element 240 and switch242. In some embodiments, the discharge circuit may selectively switchtwo or more resistors to permit different discharge rates (not shown).In some embodiments, switch 242 is periodically closed and opened topermit different discharge rates. Referring to FIG. 2, controller 120may selectively open and close switch 242 using pulse width modulation.For example, a duty cycle (e.g., proportion of a time closed) of switch242 may be increased to permit a faster discharge rate or may bedecreased to permit a slower discharge rate.

In some embodiments, the charging device may selectively switch betweenthe discharge circuit and the second converter. In some embodiments, thecontroller may selectively switch between the charging and dischargingstates using a switch (e.g., transistor, electromagnetic relay, etc.).As shown in FIG. 2, switch 202 may be a single pole change over switchconfigured for electronically coupling bulk output 130 to either secondconverter 224 or discharge circuit 226. In other embodiments, othertypes of switches (e.g., double pole change over) may be used.

In some embodiments, the charging device may simultaneously have anequalization output electronically coupled to a first battery module anda bulk output electronically coupled to a second battery module.Referring to FIG. 3, charging device 102 may be electronically coupledto battery module 104 by equalization output 128 and rig 108. As usedherein, a rig may refer to a lid having a set of buses for connectingbattery cells of a battery module in parallel, as discussed further withrespect to FIGS. 10-16. In the example, first connector 320 (e.g.,positive polarity) and second connector 322 (e.g., negative polarity) ofequalization output 128 of charging device 102 may be electronicallycoupled to first connector 324 and second connector 326 of rig 108 forbattery module 104. Similarly, first connector 330 (e.g., positivepolarity) and second connector 332 (e.g., negative polarity) of bulkoutput 130 of charging device 102 may be electronically coupled to firstterminal 302 and second terminal 304 of battery module 106. In otherembodiments, the charging device may have an equalization outputelectronically coupled to a first battery module and a bulk outputelectronically uncoupled or disconnected. Referring to FIG. 4, chargingdevice 102 may be electronically coupled to battery module 104 byequalization output 128 and rig 108. In the example bulk output 130 maybe electronically isolated from battery module 104 and battery module106.

In some embodiments, the charging device may be portable to permit usein remote locations. In some embodiments, the charging station may bedisposed in close proximity with a battery module. Referring to FIGS.5-6, charging device 102 may be stacked onto battery module 106. In theexample, battery module 104 may be placed adjacent to battery module106, for example, to reduce a footprint of the battery module system. Inother embodiments, the charging station may be spaced apart from abattery module. Referring to FIG. 7, charging device 102 may be spacedapart from battery modules 104 and 106. In the example, battery module104 may be electronically coupled to equalization output 128 using rig108 and battery module 106 may be electronically coupled to bulk output130. In other examples, battery module 104 may be electronicallydecoupled from equalization output 128 (not shown) or battery module 106may be electronically decoupled from bulk output 130 (not shown).

In some embodiments, a panel of a battery module may be removed from anenclosure of the battery module to permit attachment of a rig. Referringto FIG. 8, battery module 800 may be substantially similar to batterymodule 104 and battery module 106. For example, battery module 800 mayinclude twelve battery cells connected in series to a first terminal 802and a second terminal 804. As shown in FIGS. 8 and 9, removal of panel806 from enclosure 808 may expose cavity 902 of enclosure 808.

In some embodiments, a set of bus bars electronically couple batterycells of a battery module in series with terminals of the battery moduleto permit discharging and charging of the battery cells. Referring toFIG. 9, battery module 800 may have set of battery cells 911 thatincludes battery cells 912-934. In the example, set of battery cells 911may be electronically coupled by set if bus bars 939. In other examples,set of battery cells 911 may include different numbers of battery cells.In the example, set of bus bars 939 may include bus bars 940-964. In theexample, bus bar 940 connects an anode of battery cell 912 to a cathodeof battery cell 914, bus bar 942 connects an anode of battery cell 914to a cathode of battery cell 916, bus bar 944 connects an anode ofbattery cell 916 to a cathode of battery cell 918, bus bar 946 connectsan anode of battery cell 918 to a cathode of battery cell 920, bus bar948 connects an anode of battery cell 920 to a cathode of battery cell922, bus bar 950 connects an anode of battery cell 922 to a cathode ofbattery cell 924, bus bar 952 connects an anode of battery cell 924 to acathode of battery cell 926, bus bar 954 connects an anode of batterycell 926 to a cathode of battery cell 928, bus bar 956 connects an anodeof battery cell 928 to a cathode of battery cell 930, bus bar 958connects an anode of battery cell 930 to a cathode of battery cell 932,and bus bar 960 connects an anode of battery cell 932 to a cathode ofbattery cell 934. In the example, bus bar 962 may electronically couplea cathode of battery cell 912 to first terminal 802 and bus bar 964 mayelectronically couple an anode of battery cell 934 to second terminal804.

In some embodiments, a battery module system may include a rig forequalizing a battery cell charge of battery cells disposed in a batterymodule. Some embodiments may include any suitable number of hand screwsto attach the rig to an enclosure of a battery module. Referring to FIG.10, rig 108 may include hand screws 1010-1016 to permit a human user tosecure rig 108 onto a battery module (e.g., 104, 800, etc.). In someembodiments, hand screws are disposed on top surface 1008 of lid 1006.In the example, top surface 1008 of lid 1006 may include first connector324 (e.g., positive polarity) and second connector 326 (e.g., negativepolarity) of rig 108 for connection with first connector 320 (e.g.,positive polarity) and second connector 322 (e.g., negative polarity) ofequalization output 128.

In some embodiments, the rig may include a set of buses forelectronically coupling with battery cells of a battery module. As usedherein, a bus may be formed of any material suitable for conductingelectrical current, for example, copper, aluminum, and the like.Referring to FIG. 11, rig 108 may include first bus 1116 and second bus1118. It should be understood that although FIG. 11 depicts first bus1116 as associated with a positive ‘+’ polarity and depicts second bus1118 as associated with a negative ‘−’ polarity, the polarity associatedwith the set of buses may be different. For example, first bus 1116 maybe associated with a negative ‘−’ polarity and second bus 1118 may beassociated with a positive ‘+’ polarity (not shown).

In some embodiments, bus bars of the rig may be insulated by one or moreinsulation layers. As used herein, an insulation layer may be formed ofany dielectric material suitable for resisting a flow of electricalcurrent, for example, fiberglass, porcelain, plastics, parylene, and thelike. Referring to FIG. 11, insulating layer 1112 may be disposedbetween first bus 1116 and second bus 1118. In the example, insulatinglayer 1110 may be disposed on one side of first bus 1116 and insulatinglayer 1112 may be disposed on the other side of first bus 1116. Similar,in the example, insulating layer 1114 may be disposed on one side ofsecond bus 1118 and insulating layer 1112 may be disposed on the otherside of second bus 1118.

In some embodiments, the rig may include an edging to permit the lid ofthe rig to seal a cavity of a battery module. Referring to FIG. 11, rig108 may include edging 1102 that attaches to the lid 1006. In theexample, rig 108 may be disposed onto a battery module by a human userto seal a battery module (see FIG. 16), thereby preventing dust and dirtfrom entering into the battery module.

In some embodiments, the set of busses of the rig may include contactelements to electronically couple to battery cells of a battery module.Referring to FIG. 12, first bus 1116 may include contact element 1281for a cathode of a first battery cell (e.g., 912), contact element 1283for a cathode of a second battery cell (e.g., 914), and contact element1285 for a cathode of a third battery cell (e.g., 916). As shown,contact element 1281 of first bus 1116 may be representative of othercontact elements of first bus 1116. For example, contact element 1281may have a shape, thickness, material, and the like of contact elements1283 and 1285, as well as other contact elements of first bus 1116. Itshould be understood that the first bus may include any suitable numberof contact elements. In some embodiments, first bus 1116 may include acontact element for each battery cell of a battery module.

Similarly, second bus 1118 may include contact element 1280 for an anodeof a first battery cell (e.g., 912), contact element 1282 for an anodeof a second battery cell (e.g., 914), and contact element 1284 for ananode of a third battery cell (e.g., 916). As shown, contact element1280 of second bus 1118 may be representative of other contact elementsof second bus 1118. For example, contact element 1280 may have a shape,thickness, material, and the like of contact elements 1282 and 1284, aswell as other contact elements of second bus 1118. It should beunderstood that the second bus may include any suitable number ofcontact elements. In some embodiments, second bus 1118 may include acontact element for each battery cell of a battery module.

In some embodiments, an elongated portion of the first bus and/or thesecond bus may extend along a first axis. Referring to FIG. 12,elongated portion 1216 of first bus 1116 and elongated portion 1218 ofsecond bus 1118 extend in one or more directions parallel to first axis1202. In some embodiments, contact elements of the first bus and/or thesecond bus may extend in one or more directions parallel to second axis1204. In the example, first axis 1202 and second axis 1204 areperpendicular. Referring to FIG. 12, contact element 1281 of first bus1116 may extend away from elongated portion 1216 of first bus 1116 in adirection parallel to second axis 1204. Similarly, in the example,contact element 1282 of second bus 1118 may extend away from elongatedportion 1218 of second bus 1118 in a direction parallel to second axis1204. As shown, in some embodiments, contact elements of the first busand/or the second bus may extend in different directions along thesecond axis. Referring to FIG. 12, contact element 1281 of first bus1116 extends along one direction of second axis 1204 (e.g., left) whilecontact element 1283 of first bus 1116 extends along the other directionof second axis 1204 (e.g., right). Similarly, contact element 1280 ofsecond bus 1118 extends along one direction of second axis 1204 (e.g.,right) while contact element 1282 of second bus 1118 extends along theother direction of second axis 1204 (e.g., left).

In some embodiments, the buses of the rig may be stacked. Referring toFIG. 12, first bus 1116 and second bus 1118 are stacked in a directionalong third axis 1206, which may be perpendicular to first axis 1202 andsecond axis 1204. In some embodiments, the buses are stacked withinsulating layers. Referring to FIG. 12, first bus 1116, second bus1118, and insulating layers 1110-114 are stacked along third axis 1206.

In some embodiments, contact elements of a bus of the rig are interwovenwith contact elements of another bus of the rig to permit a coupling ofbattery cells disposed in a battery module to have alternating cathodeand anode connections to facilitate a series connection. Referring toFIG. 12, contact element 1282 of second bus 1118 is disposed betweencontact elements 1281 and 1285 of first bus 1116. Similarly, contactelement 1283 of first bus 1116 is disposed between contact elements 1280and 1284 of second bus 1118.

In some embodiments, anodes and cathodes of battery cells of a batterymodule may be alternating to facilitate electronically coupling thebattery cells in series. Referring to FIG. 13, first anode 1380 ofbattery cell 912 is spaced closer to second cathode 1383 of battery cell914 than second anode 1382 of battery cell 914. In the example, firstcathode 1381 of battery cell 912 is spaced closer to second anode 1382of battery cell 914 than second cathode 1383 of battery cell 914.Similarly, as shown in FIG. 13, second anode 1382 of battery cell 914 isspaced closer to third cathode 1385 of battery cell 916 than third anode1384 of battery cell 916. In the example, second cathode 1383 of batterycell 914 is spaced closer to third anode 1384 of battery cell 916 thanthird cathode 1385.

In some embodiments, battery cells of a battery module may be aligned inthe battery module to facilitate electrical coupling of the batterycells. In some embodiments, a cathode of a first battery, an anode of asecond battery, and a cathode of a third battery are aligned. Referringto FIG. 13, first anode 1380 of battery cell 912, second cathode 1383 ofbattery cell 914, and third anode 1384 of battery cell 916 are alignedalong first axis 1202. In the example, first cathode 1381 of batterycell 912, second anode 1382 of battery cell 914, and third cathode 1385of battery cell 916 are aligned along first axis 1202. In someembodiments, a cathode and an anode of a battery cell are aligned.Referring to FIG. 13, first anode 1380 of battery cell 912 and firstcathode 1381 are aligned along second axis 1204. In the example, secondanode 1382 of battery cell 914 and second cathode 1383 are aligned alongsecond axis 1204. In the example, third anode 1384 of battery cell 916and third cathode 1385 are aligned along second axis 1204.

In some embodiments, contact elements of a rig may extend away from abottom surface of a lid of a rig. Referring to FIG. 13, contact elements1280-1285 may extend away from bottom surface 1308 of lid 1006 of rig108. In some embodiments, contact elements of a rig may extend away froma bottom surface of a lid of a rig and towards battery cells of abattery module. Referring to FIGS. 14 and 15, contact element 1281 mayextend towards battery cell 912. In the example, other contact elementsmay extend towards battery cell 912 (not shown) and/or other towardsother battery cells (not shown).

In some embodiments the rig may be attached to the battery module. Insome embodiments, a human user may attach the rig to an enclosure of abattery module. Referring to FIG. 14, rig 108 may be attached toenclosure 808. In some embodiments, one or more fasteners may be used toattach and/or secure the rig to the battery module. Referring to FIG.14, a human user may thread hand screws 1010-1016 into enclosure 808. Insome embodiments, threading the hand screws may force the rig downwardinto a cavity of the enclosure of a battery module such that a contactelement of the rig may electronically couple with battery cells of abattery module. In other embodiments, the fasteners may be a bolt (notshown), pin, clamp, and the like. Referring to FIGS. 14-16, threading ofhand screws 1010-1016 may move rig 108 into cavity 902 (see FIG. 9) ofenclosure 808. In the example, such a threading moves contact element1281 into direct contact with first cathode 1381 of battery cell 912.

In some instances the battery module may be in a series configuration tofacilitate bulk maintenance (e.g., charging and/or discharging) ofbattery cells of the battery module. Referring to FIG. 17, in the seriesconfiguration shown, set of bus bars 939 (e.g., bus bars 940-964 of FIG.9) electronically couple set of battery cells 911 (e.g., battery cells912-934 of FIG. 9) in series with bulk output 130. In the example,charging device 102 outputs a second voltage (e.g., 40 volts) to bulkoutput 130 to change a charge level of set of battery cells 911. Inother embodiments, the battery module may be in a parallel configuration(see FIGS. 21-22).

In some embodiments, charging device 102 may selectively switch betweena charging state and a discharging state. In some embodiments, thecontroller may selectively switch between the charging and dischargingstates using a switch (e.g., transistor, electromagnetic relay, etc.).As shown in FIG. 17, switch 202 may be a single pole change over switch.In other embodiments, other types of switches (e.g., double pole changeover) may be used. In the example, in the series configuration of thebattery module, controller 120 may cause switch 202 to electronicallycouple discharge circuit 226 to the bulk output 130 for bulk dischargingone or more battery cells of set of battery cells 911. Alternatively, inthe series configuration of the battery module, controller 120 may causeswitch 202 electronically couple converter 224 to the bulk output 130for bulk charging one or more of set of battery cells 911 (see FIGS.19-20).

In some embodiments, in the discharging state, a charge level of one ormore battery cells of a battery module may be reduced. Referring to FIG.17, set of battery cells 911 of battery module 800 may have initialcombined charge level 1730 of about seventy-five percent of a maximumcharge level of battery module 800, battery cell 916 may have initialcharge level 1720 of about fifty percent of a maximum charge level ofbattery cell 916, and battery cell 924 may have initial charge level1710 of about one-hundred percent of a maximum charge level of batterycell 924. In the example, as shown in FIG. 18, discharge circuit 226 maydischarge set of battery cells 911 such that battery module 800 may havecharge level 1830 of about fifty percent of a maximum charge level ofbattery cell 912, battery cell 916 may have charge level 1820 of abouttwenty percent of a maximum charge level of battery cell 916, andbattery cell 924 may have charge level 1810 of about seventy-fivepercent a maximum charge level of battery cell 924. It should beunderstood that, in some embodiments, in the discharging state, thecharging device may transfer energy from the battery module to anelectric grid connection to permit line regeneration. For example,charging device 102 may transfer energy from battery module 800 to ACsupply 110 (see FIG. 1) using a bi-direction ac-dc converter (e.g.,224).

In some embodiments, in the charging state, a charge level of one ormore battery cells of a battery module may be increased. Referring toFIG. 19, set battery cells 911 of battery module 800 may have initialcombined charge level 1930 of about seventy-five percent of a maximumcharge level of battery module 800, battery cell 916 may have initialcharge level 1920 of about fifty percent of a maximum charge level ofbattery cell 916, and battery cell 924 may have initial charge level1910 of about one-hundred percent of a maximum charge level of batterycell 924. In the example, as shown in FIG. 20, second converter 224 ofcharging device 102 may charge set of battery cells 911 such thatbattery module 800 may have combined charge level 2030 of aboutone-hundred percent of a maximum charge level of battery module 800,battery cell 916 may have charge level 2020 of about seventy-fivepercent of a maximum charge level of battery cell 916, and battery cell924 may have charge level 2010 of about one-hundred-twenty-five (e.g.,overcharged) percent a maximum charge level of battery cell 924.

In some instances the battery module may be in a parallel configurationto facilitate equalization of battery cells of the battery module.Referring to FIG. 21, in the parallel configuration shown, rig 108 mayelectronically couple set of battery cells 911 in parallel withequalization output 128. In the example, charging device 102 outputs asecond voltage (e.g., 3.3 volts) to equalization output 128 to change acharge level of set of battery cells 911. In other embodiments, thebattery module may be in a series configuration (see FIGS. 17-20).

In some embodiments, in the parallel configuration, a charge level ofone or more battery cells of a battery module may be increased.Referring to FIG. 21, set of battery cells 911 of battery module 800 mayhave initial combined charge level 2130 of about seventy-five percent ofa maximum charge level of battery module 800, battery cell 916 may haveinitial charge level 2120 of about fifty percent of a maximum chargelevel of battery cell 916, and battery cell 924 may have initial chargelevel 2110 of about one-hundred percent of a maximum charge level ofbattery cell 924. In the example, as shown in FIG. 22, first converter222 of charging device 102 may charge set of battery cells 911 such thatbattery module 800 may have combined charge level 2230 of aboutone-hundred percent of a maximum charge level of battery module 800,battery cell 916 may have charge level 2220 of about one-hundred percentof a maximum charge level of battery cell 916, and battery cell 924 mayhave charge level 2210 of about one-hundred percent a maximum chargelevel of battery cell 924. That is, the equalization output and rig maybe used to equalize or balance charge levels of battery cells of abattery module to reduce overcharging of battery cells and/or to improvean amount of energy stored in a battery module.

It should be understood that, in some embodiments, a charge rate in theparallel configuration may be different than a charge rate in theparallel configuration. For example, charging device 102 may chargebattery module 800 in the parallel configuration (see FIGS. 21-22) usinga faster charge rate than battery module 800 in the series configuration(see FIGS. 17-20). Further, in some embodiments, a charging device maymeasure (e.g., using a sensor circuit) and record the different chargingrates to detect electrical characteristics of the battery module and/orone or more battery cells of the battery module. For example, localterminal 126 may record such charging rates in data store 150 (seeFIG. 1) and/or transmit such charging rates to remote data store 140using one or more networks 144 (see FIG. 1).

While various embodiments of the invention have been described, thedescription is intended to be exemplary, rather than limiting and itwill be apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible that are within the scopeof the invention. Accordingly, the invention is not to be restrictedexcept in light of the attached claims and their equivalents. Also,various modifications and changes may be made within the scope of theattached claims.

We claim:
 1. A module maintenance system comprising: a battery modulecomprising at least a first battery cell and a second battery cell; acharging device comprising a bulk output and an equalization output;wherein the battery module has a series configuration and a parallelconfiguration; wherein, in the parallel configuration, the chargingdevice outputs a first voltage to the equalization output to equalizecharge levels of the first and second battery cells; wherein, in theseries configuration, the charging device outputs a second voltage tothe bulk output to modify charge levels of the first and second batterycells; and wherein the second voltage is greater than the first voltage.2. The module maintenance system according to claim 1, wherein, in theseries configuration, the charging device is configured to selectivelyswitch between a charging state and a discharging state; wherein, in thecharging state of the charging device, the charging device outputs thesecond voltage on the bulk output; and wherein, in the discharging stateof the charging device, the charging device switches a dischargingcircuit to the bulk output for discharging the first battery, the secondbattery cell, or a combination thereof.
 3. The module maintenance systemaccording to claim 2, wherein the discharge circuit includes a resistiveelement; and wherein, in the discharging state of the charging device,the charging device switches the resistive element in series with thefirst and second battery cells.
 4. The module maintenance systemaccording to claim 2, wherein, in the discharging state of the chargingdevice, the charging device transfers energy from the first and secondbattery cells to an electric grid connection.
 5. The module maintenancesystem according to claim 2, wherein, in the discharging state of thecharging device, the charging device measures a discharge rate of thefirst battery cell; wherein, in the charging state of the chargingdevice, the charging device measures a first charge rate of the firstbattery cell; and wherein, in the parallel configuration, the chargingdevice measures a second charge rate of the first battery cell.
 6. Themodule maintenance system according to claim 5, wherein the chargingdevice includes a computing device, the computing device including adata store; and wherein the computing device stores the discharge rate,the first charge rate, and the second charge rate in the data store. 7.The module maintenance system according to claim 6, wherein the chargingdevice transmits the discharge rate, the first charge rate, and thesecond charge rate to a remote data store using one or more networks.